Prefabricated masonry covered structural wall panel

ABSTRACT

A prefabricated masonry covered structural wall panel is disclosed, comprising a plurality of framing members extending in a parallel relationship to each other and to which are secured metallic skeletal supports. A perforated metallic cladding, attached to the metallic skeletal supports, is covered with a plurality of thin bricks. The prefabricated panel can be used as an integral structural part of a building structure or in a curtain wall.

FIELD OF THE INVENTION

The present invention relates to the field of building construction, more precisely to prefabricated brick covered wall panels.

BACKGROUND OF THE INVENTION

To meet deadlines and cope with spatial constraints, the construction industry has introduced prefabricated wall panels supporting pre-installed or shop installed thin brick sections. By prefabricated, it is meant a factory-assembled panel, as opposed to onsite construction. Manufacturers make these panels and these brick sections directly in the factory, manually or using mechanized equipment. As the panels and the sections are manufactured in factories, off-site, construction workers can spend less time on construction sites, thus offering a solution to the existing construction worker shortage and an improvement to the quality of the product.

As prefabricated panels are expected to meet specific requirements in terms of thickness, thermal isolation, weathering, lightness and strength, the construction industry is working on the improvement of existing products and fabrication techniques.

Many decorative masonry covered panels can be found in the prior art. The following patents disclose examples of these prior art decorative panels: U.S. Pat. No. 2,825,221 (BROUK), U.S. Pat. No. 4,407,104 (FRANCIS), U.S. Pat. No. 5,715,637 (HESTERMAN et al.) and U.S. Pat. No. 6,240,691 (HOLZKAEMPER et al.). In some of these patents, the thin bricks are mounted on a wood surface, on rigid plastic foam insulation surfaces or on sheet metal surfaces affixed to a wooden structure. Among these patents, there are also provided panels made of fireproof components designed to address the need for non-combustible and fire resistant construction. However, these panels are mostly decorative and, as they are made of light components, they are not designed to be part of the building supporting structure.

U.S. Pat. No. 6,412,244 (NOLAN) discloses a prefabricated modular wall element comprising a precast reinforced concrete wall panel having a front face partially embedding a plurality of spaced-apart individual slabs of stone or brick. A pair of spaced-apart support legs is provided at a bottom of the wall panel for keying into a concrete foundation to support the wall element.

U.S. Pat. No. 4,642,960 (WALLOVER) also discloses a panel, which is a structural supporting element in a building construction. WALLOVER provides a panel including a plurality of support members or studs preferably formed by metal channels and a five-strand layer wire mesh. The wire mesh is encapsulated with cement to form a ferrocement panel and decorative facing tiles are secured to an outer face of the ferrocement panel by a layer of grouting. The ferrocement panel provides the structural load bearing component for the prefabricated panel for supporting the facing tiles and eliminates the need for a separate substrate which heretofore spanned the support members and provided the structural support.

One drawback with these last two panels, which use cement in their structural part, is that the preparation and transportation of cement may involve several constraints, for example, there is always a risk that the panel crack and break during transportation or installation. Cemented panels are also generally heavy components.

Therefore, there is still a need for a prefabricated masonry covered wall panel which can be used as a decorative element of the building as well as a structural element thereof, and which does not present the drawbacks of cement panels.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a prefabricated masonry covered structural wall panel fulfilling the above-mentioned need.

According to one aspect of the present invention, that object is achieved with a prefabricated wall panel, comprising a plurality of structural framing members extending in a substantially parallel relationship to each other. At least one metallic skeletal support has an interior side secured to an exterior side of the framing members. A perforated metallic cladding is attached to an exterior side of the at least one metallic skeletal support and a plurality of thin bricks are secured to an exterior side of the cladding. The thin bricks are covering the exterior side of the cladding in a predetermined pattern.

By prefabricated panel, it is meant that the panel is manufactured in advance, especially in standard sections that can be easily shipped and assembled, as opposed to onsite construction.

By structural framing member, it is meant a load-bearing framing member or a framing member that can bear load in a building, as opposed to a framing member used in a solely decorative assembly. As such, the structural framing members as used in the present description also include framing members used in curtain wall assembly.

According to another aspect of the invention, there is also provided a method for manufacturing a prefabricated masonry covered structural wall panel including the steps of:

-   -   a) providing a plurality of framing members and extending the         same in a substantially parallel relationship to each other,         each of the framing members having an interior side opposed to         an exterior side;     -   b) providing at least one metallic skeletal support having an         interior side and an exterior side, and securing the interior         side of the at least one metallic skeletal support to the         exterior side of the framing members;     -   c) securing a perforated metallic cladding to the exterior side         of the at least one metallic skeletal support, the perforated         metallic cladding having an interior side and an exterior side;         and     -   d) securing a plurality of thin bricks to the exterior side of         the cladding for covering the exterior side of the cladding with         the bricks in a predetermined pattern.

One advantageous feature of the present invention is that the prefabricated panel forms a structural wall section that can be integrated in the building construction structure, as a component of the supporting structure. This panel is also easy to transport and install, as it is less likely to crack, than the corresponding cemented portion in the cement-made panels of the prior art.

Another advantageous feature of the present invention is that it provides a solution to evacuate the water stagnating between the layer of brick and its skeletal support. Indeed, thanks to the perforations in the support of the cladding, water that may seep through the layer of brick exits through the perforations and is then evacuated out of the building facade.

Also thanks to the fact that the panel is shop-assembled, the masonry work is greatly simplified. Indeed, the installation of the bricks can be done while the metallic support and cladding are laid flat on a horizontal surface. This reduces the risks that the bricks unstuck and facilitates the work of the mason.

Furthermore, when the framing members are made of metal, the panels of the invention also have the advantage of being considered incombustible.

Other features and advantages of the present invention will be better understood upon reading preferred embodiments thereof with reference to the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing the construction of a building using prefabricated panels according to a preferred embodiment of the invention.

FIG. 2 is a cross-sectional view of the prefabricated panel shown in FIG. 1.

DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

Referring to FIG. 1, the construction of a building using prefabricated wall panels (10) according to a preferred embodiment of the invention is shown. As can be appreciated, the panels (10) are shipped from the shop to the site of construction where they are lifted vertically by means of a crane (40) and placed side-by-side along with foundations (60) initially built in the ground for receiving the panels. Prior to the shipment of the panels (10), I-beams (50), joists (52) and columns (54) are assembled to form the framework of the building. When the panels (10) are shipped to the site of construction, they are placed adjacently and secured to the structure (50, 52 and/or 54). As can be appreciated from FIG. 1, a prefabricated masonry panel (10) according to the invention can be used in a building structure such as a multi-stories residential or commercial building as an element of the structure of the building. It is however worth mentioning that the wall panels can still be used as a curtain wall to be affixed to a pre-existing building structure. The panels (10) according to the present invention can also be used in combination with other type of wall panels (11), such as corrugated metal sheet.

Turning now to FIG. 2, the wall panel (10) comprises a plurality of structural framing members (16), two of these are illustrated in FIG. 2. The number of framing members (16) in a panel (10) depends on the width of the panel to be manufactured. As apparent to any person in the art, the wider the panel, the greater is the number of framing members to be used. The panel (10) also comprises at least one metallic skeletal support (20) secured to the framing members (16) and a perforated metallic cladding (14) attached to the skeletal support (20). The cladding (14) is covered with a plurality of thin bricks (24). Each of these components of the panel (10) will now be described in more detail.

The framing members (16) extend in a substantially parallel relationship to each other, and when the panel (10) is installed, they are extending in a vertical direction. They are preferably made of metal. In such a case, they are particularly advantageous for use in non-combustible and fire-resistant constructions. Any metallic upright posts such as studs or columns of hot-rolled structural steel can be used for the framing members (16).

The at least one metallic skeletal support (20) preferably consists of vertical bars having a generally Z-shaped cross section. In the embodiment illustrated, each skeletal support (20) is associated with a respective framing member (16), and has an interior side secured to an exterior side of the framing members (16) by means of mechanical fasteners. It is worth mentioning that interior side and exterior side both refer respectively to the inside and outside of the building. The mechanical fasteners are screws (30) or bolts. In another embodiment of the invention, not illustrated, the at least one metallic skeletal support (20) comprises a corrugated metallic sheet with the corrugations extending in a vertical direction. In that particular case, the bottom of some grooves of the corrugated metallic sheet is secured to a respective framing member (16) by means of mechanical fasteners such as screws or bolts. By metallic skeletal supports, it is meant supports capable of supporting the load of the layer of brick. In another embodiment, not illustrated, and used mainly in residential and commercial constructions, the skeletal support is made of metal tracts and furring.

Although not clearly illustrated in the figures, the perforated metallic cladding (14) is attached to the exterior side of the metallic skeletal supports (20) by means of mechanical fasteners such as screws or bolts. The cladding (14) is preferably pre-painted and has a thickness of about 20 ga.

The thin bricks (24) are secured to the exterior side of the cladding (14) and cover the same in a predetermined pattern. The thin bricks (24) are secured to the cladding (14) by means of a glue layer (25) which fills at least a portion of the perforations of the cladding (14) and forms protuberances (26) that project on the interior side of the cladding (14), thereby opposing a mechanical resistance to a detachment of the glue layer (25). Since the panel (10) is completely assembled in shop, the installation of the thin bricks (24) can be performed while the cladding (14) is laid flat on a horizontal surface. This reduces the risks that the bricks unstuck and facilitates the work of the mason. As for conventional brick walls, the spaces between the bricks (24) can be filled with mortar that advantageously can match the colour of the bricks (24). This filling step is also greatly facilitated by the fact that it is performed while the cladding (20) is laid flat.

The thin bricks (24) preferably have a thickness of about ½inch and are made of clay or any other appropriate material such as concrete. It is understood that the term “brick” may also refer to stones of various kinds used on the facade of buildings. Although the bricks (24) shown in the illustrated embodiment have a traditional rectangular shape, it is understood that the present invention could make use of bricks of any shape as may be selected to obtain a particular visual appearance of the finished building. It is also understood that the bricks of a same panel do not need to be all of the same shape or appearance.

The panel (10) with the framing members (16), the metallic skeletal support (20) and the perforated metallic cladding (14) covered with the bricks form a metallic support or wall section meant to be an integral part of the building structure capable of supporting structural elements, for example roofs, floors, etc. The panel (10) is integrated in the building construction structure, as a component of the supporting structure. In a preferred embodiment, a plurality of such panels (10) is installed side-by-side in order to form a visually continuous facade. It will be understood by a person skilled in the art that various techniques may be used in order to ensure visual continuity at the joints between neighbouring panels. These panels (10) can also be used in combination with other types of prefabricated wall panels, for example with panels having an outer finish made of corrugated metal sheets.

Still referring to FIG. 2, a water resistant support sheet (18), or substratum and a rigid insulating layer (32) are preferably provided between the framing members (16) and metallic skeletal support (20).

It is worth mentioning that if the panel is to be used as a curtain wall panel, it is composed of lighter components capable of structurally supporting the weight of the panel and securing the same to the pre-existing structure of the building. The panels are then installed on site according to the desired architectural result.

The perforated metallic cladding (14) provides a solution to evacuate the water stagnating between the layer of brick and its skeletal support. Water that may seep through the layer of brick exits through the perforations and is then evacuated out of the building facade.

A panel according to the invention is manufactured according to the following method which comprises the steps of:

-   -   a) providing a plurality of framing members (16) and extending         the same in a substantially parallel relationship to each other,     -   b) securing at least one metallic skeletal support (20) to an         exterior side of the framing members (16), preferably by means         of mechanical fasteners such as screws or nuts;     -   c) optionally, extending a water resistant layer (18) between         the framing members and the metallic skeletal support (20);     -   d) securing a preferably pre-painted perforated metallic         cladding (14) to the exterior side of the metallic skeletal         support (20);     -   e) optionally, extending a rigid insulating layer (32) between         the water resistant layer (18) and the perforated metallic         cladding (14);     -   f) securing a plurality of thin bricks (24) to an exterior side         of the cladding (14), preferably by laying a glue layer on the         exterior side of the cladding (14), for covering the exterior         side of the cladding with the bricks in a predetermined pattern;         and     -   g) preferably filling at least a portion of the perforations of         the cladding (14) and forming protuberances that project on the         interior side of the cladding (14), thereby opposing a         mechanical resistance to a detachment of the glue layer.

Although a preferred embodiment of the present invention has been described in detail herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to this precise embodiment and that various changes and modifications may be effected therein without departing from the scope or spirit of the present invention. 

1. A prefabricated masonry covered structural wall panel, comprising: a plurality of structural framing members extending in a substantially parallel relationship to each other, each of said framing members having an interior side opposed to an exterior side; at least one metallic skeletal support having an interior side and an exterior side, the interior side of said at least one metallic skeletal support being secured to the exterior side of the framing members; a perforated metallic cladding attached to the exterior side of the at least one metallic skeletal support, said perforated metallic cladding having an interior side and an exterior side; and a plurality of thin bricks being secured to the exterior side of the cladding, and covering said exterior side of the cladding in a predetermined pattern.
 2. The prefabricated wall panel according to claim 1, comprising a plurality of said metallic skeletal supports each including a vertical bar having a generally Z-shaped cross section.
 3. The prefabricated wall panel according to claim 1, wherein the at least one metallic skeletal support comprises a corrugated metallic sheet.
 4. The prefabricated wall panel according to claim 1, wherein the interior side of the at least one metallic skeletal support is secured to the exterior side of the framing members by means of mechanical fasteners selected from the group consisting of screws and nuts.
 5. The prefabricated wall panel according to claim 1, wherein the plurality of thin bricks is secured to said cladding by means of a glue layer laid on the exterior side of the cladding.
 6. The prefabricated wall panel according to claim 5, wherein the glue layer fills at least a portion of the perforations of said cladding and forms protuberances that project on the interior side of the cladding, thereby opposing a mechanical resistance to a detachment of the glue layer.
 7. The prefabricated wall panel according to claim 1, wherein the cladding is attached to the exterior side of the at least one metallic skeletal support by means of mechanical fasteners selected from the group consisting of screws and nuts.
 8. The prefabricated wall panel according to claim 1, wherein the perforated metallic cladding has a thickness of about 20 ga.
 9. The prefabricated wall panel according to claim 1, further comprising a water resistant layer extending between the exterior side of the framing members and the interior side of the at least one metallic skeletal support.
 10. The prefabricated wall panel according to claim 9, further comprising a rigid insulating layer extending between the water resistant layer and the perforated metallic cladding.
 11. A method for manufacturing a prefabricated masonry covered structural wall panel including the steps of: a) providing a plurality of structural framing members extending in a substantially parallel relationship to each other, each of said framing members having an interior side opposed to an exterior side; b) providing at least one metallic skeletal support having an interior side and an exterior side, and securing the interior side of the at least one metallic skeletal support to the exterior side of the framing members; c) securing a perforated metallic cladding to the exterior side of the at least one metallic skeletal support, said perforated metallic cladding having an interior side and an exterior side; and d) securing a plurality of thin bricks to the exterior side of said cladding for covering the exterior side of the cladding with said bricks in a predetermined pattern.
 12. The method according to claim 11, comprising the step of securing the interior side of the at least one metallic skeletal support to the exterior side of the framing members by means of mechanical fasteners selected from the group consisting of screws and nuts.
 13. The method according to claim 12, comprising the step of securing the plurality of thin bricks to said cladding by laying a glue layer on the exterior side of the cladding.
 14. The method according to claim 13, comprising the step of filling at least a portion of the perforations of said cladding and forming protuberances that project on the interior side of the cladding, thereby opposing a mechanical resistance to a detachment of the glue layer.
 15. The method according to claim 11, comprising the step of extending a water resistant layer between the exterior side of the framing members and the interior side of the at least one metallic skeletal support.
 16. The method according to claim 15, comprising the step of extending a rigid insulating layer between the water resistant layer and the perforated metallic cladding. 